REMOVAL & INSTALLATION
See Figure 1
Before the brake booster is reinstalled, the brake booster pushrod must be adjusted so that there is zero clearance between it and the master cylinder. This adjustment requires the use of a brake booster pushrod gauge such as SST No. 09737-00010 or its equivalent.
- If necessary, remove the instrument lower finish panel, air duct and floor mats to gain access to the brake booster linkage.
- Remove the master cylinder from the vehicle.
- On some models, loosen the clamp screw and push down on the charcoal canister slightly to access the booster lower bolts.
- Loosen the hose clamp and disconnect the vacuum hose from the booster.
- On 1983-86 vehicles, disconnect the wiring from the brake light switch.
- From inside the vehicle, remove the pedal return spring, clip and the clevis pin with the locknut. Remove the four mounting nuts and the clevis.
- Pull the booster and gasket from the fire wall.
Adjust the length of the brake booster push rod as follows:
- Set the measuring tool (09737-00010 or equivalent) on the master cylinder with the gasket and lower the pin of the tool until it lightly contacts the position.
- Turn the measuring tool upside-down and position it onto the booster.
- Measure the clearance between the booster push rod and the pin head of the tool. There must be zero clearance. To obtain zero clearance, adjust the push rod length until the push rod light contacts the head of the pin.
- Connect the clevis pin with locknut to the booster and install the brake booster with a new gasket.
- Install the mounting nuts and tighten them to 9 ft. lbs. (13 Nm).
- Insert the clevis pin through the clevis and the brake pedal. Secure the pin with the retaining clip.
- Install the pedal return spring. On 1983-86 vehicles, connect the brake light switch wiring.
- Install the instrument lower finish panel and air duct.
- Place the charcoal canister into its original position if removed.
- Install the master cylinder and connect the vacuum hose.
- Fill the brake fluid reservoir to the proper level with clean brake fluid and bleed the master cylinder as described in this Section.
- Check for leaks. Check and/or adjust the brake pedal.
- Perform a brake booster operational check and air tightness check as detailed below.